User Guide IM/AK1/23 Rev. N AK102 and AK103 Gas analyzer … · 2018. 5. 9. · 3.1.1 Model 6553...

User Guide IM/AK1/23 Rev. N

AK102 and AK103Gas analyzer systems for Hydrogen-cooled alternators

The CompanyWe are an established world force in the design and manufacture of measurement products for industrial process control, flow measurement, gas and liquid analysis and environmental applications.

As a part of ABB, a world leader in process automation technology, we offer customers application expertise, service and support worldwide.

We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and support.

The quality, accuracy and performance of the Company’s products result from over 100 years experience, combined with a continuous program of innovative design and development to incorporate the latest technology.

EN ISO 9001:2008

Cert. No. Q 05907

EN 29001 (ISO 9001)

Lenno, Italy – Cert. No. 9/90A

Stonehouse, U.K.

Electrical SafetyThis equipment complies with the requirements of EN 61010-1:2010 'Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use'. If the equipment is used in a manner NOT specified by the Company, the protection provided by the equipment may be impaired.

SymbolsOne or more of the following symbols may appear on the equipment labelling:

Warning – Refer to the manual for instructions Direct current supply only

Caution – Risk of electric shock Alternating current supply only

Protective earth (ground) terminal Both direct and alternating current supply

Earth (ground) terminalThe equipment is protected through double insulation

Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of the Technical Publications Department.

Health and Safety

To ensure that our products are safe and without risk to health, the following points must be noted:

1. The relevant sections of these instructions must be read carefully before proceeding.

2. Warning labels on containers and packages must be observed.

3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the information given.

4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure and/or temperature.

5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures must be used.

6. When disposing of chemicals ensure that no two chemicals are mixed.

Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may be obtained from the Company address on the back cover, together with servicing and spares information.

1

CONTENTS

1 INTRODUCTION .......................................................... 2

2 DESCRIPTION.............................................................. 32.1 Model 6553 Display Unit ..................................... 3

2.1.1 Range Display ....................................... 32.2 Model 006540203 or 006548000

Katharometer Analyzer Panel .............................. 42.3 Model 4234 500/4234 501

Power Supply Units (PSU) ................................... 42.4 Remote Indicator/Controllers .............................. 4

3 PREPARATION ............................................................. 53.1 Identification ....................................................... 5

3.1.1 Model 6553 Display Unit ....................... 53.1.2 Model 006540 203 or 006548 000

Katharometer Analyzer Panel ................ 53.1.3 Model 4234 Power Supply Unit ............. 63.1.4 AK10x Ordering Information .................. 7

4 MECHANICAL INSTALLATION .................................... 84.1 Locating and Mounting System Items ................. 8

4.1.1 Model 6553 Display Unit ....................... 84.1.2 Katharometer Analyzer Panel ................ 94.1.3 Model 4234 Power Supply Unit ........... 104.1.4 Cubicle Mounted System .................... 11

4.2 Sample Gas Interconnections ........................... 12

5 ELECTRICAL INSTALLATION .................................... 135.1 Electrical Interconnections ................................ 13

5.1.1 Model 6553 Display Unit ..................... 145.1.2 Model 006540 203 and 0065480 00

Katharometer Analyzer Panel .............. 175.1.3 Model 4234 Power Supply Unit ........... 18

5.2 Intrinsically Safe Requirements .......................... 195.2.1 Cable Requirements ............................ 195.2.2 Interconnection Cables ....................... 195.2.3 Installing Remote Ancillary Items ......... 195.2.4 Full Intrinsically Safe Requirements ...... 19

6 SETTING UP............................................................... 206.1 Katharometer Analyzer Panel –

Filling the Drying Chamber ................................ 206.2 Setting Sample Flow ......................................... 206.3 Electrical Checks .............................................. 21

6.3.1 Power Supply Unit Output ................... 216.3.2 Zener Diode Safety Barrier Devices ..... 216.3.3 Checking System Earth ....................... 21

7 CONTROLS & DISPLAYS .......................................... 227.1 Displays ............................................................ 227.2 Switch Familiarization ........................................ 227.3 Main Isolator Switch, Toggle switches and

Miniature Circuit Breakers (MCBs) ..................... 23

8 START-UP ................................................................... 248.1 Instrument Start-Up .......................................... 248.2 Alarm Set Point ................................................. 24

8.2.1 Type of Alarm Action ........................... 248.2.2 Hydrogen alarm Set Point ................... 24

8.3 Electrical Calibration ......................................... 248.4 Gas Calibration ................................................. 25

8.4.1 Introduction ......................................... 258.4.2 Gas Range Calibration ........................ 25

9 OPERATION ............................................................... 269.1 Normal .............................................................. 26

9.1.1 Purging of Hydrogen Coolant Gas ....... 269.1.2 Filling with Hydrogen Coolant Gas ....... 26

9.2 Range 1 Operating Page .................................. 279.3 Range 2 Operating Page .................................. 279.4 Range 3 Operating Page .................................. 27

10 PROGRAMMING ........................................................ 2810.1 Access to Secure Parameters ........................... 2910.2 Language Page ................................................ 2910.3 Set Up Outputs Page........................................ 3010.4 Electrical Calibration Page ................................ 31

11 MAINTENANCE .......................................................... 3211.1 General Maintenance ........................................ 32

11.1.1 Pressure .............................................. 3211.1.2 Flow .................................................... 3211.1.3 Leaks .................................................. 3211.1.4 Vibration .............................................. 3211.1.5 Contamination ..................................... 3211.1.6 Ambient Temperature .......................... 3211.1.7 Bridge Current .................................... 32

11.2 Diagnostic Tests ............................................... 3311.2.1 Checking Output of the PSU ............... 3311.2.2 Checking Integrity of Zener

Diode Safety Barrier Devices ............... 3311.2.3 Checking the Katharometer Output ..... 33

11.3 Routine Maintenance ........................................ 3311.3.1 Hydrogen Katharometer

Calibration ........................................... 3311.3.2 Purge Gas Katharometer

Calibration ........................................... 3311.3.3 Changing Desiccant in

Drying Chamber .................................. 3311.4 Repair Maintenance .......................................... 34

11.4.1 Removing Liquid from KatharometerMeasurement Block ............................ 34

11.4.2 Removal/Replacementof an Indicator Unit .............................. 34

11.4.3 Error Messages ................................... 34

12 SPARE PARTS LIST ................................................... 3512.1 Consumables ................................................... 3512.2 Routine Maintenance Parts ............................... 3512.3 Repair Maintenance Parts ................................. 35

13 CERTIFICATES ........................................................... 36

14 SPECIFICATION ......................................................... 37

2

Note. CO2 is refered to throughout this manual as thepurge gas. However, other gases such as Argon orNitrogen may be used instead.

Caution. This operating manual applies only to thosesystems that have been designed and constructed tothe standards specified in the schedules of the ATEXcertificates listed. The separate units to which thesecertificates apply are clearly identifiable by modelnumbers and the data on the identification and ATEXcertification labels fixed to them. Other combinations ofsimilar equipment built to any earlier specifications arenot covered by BASEEFA certificate number BAS Ex01E2044. This is particularly important where newreplacement units are to be incorporated into existinginstallations covered by any earlier certificationstandards. If in any doubt about the installation ofparticular combinations of certified equipment, contactthe Company for advice before proceeding.It is essential that units are installed strictly inaccordance with the appropriate standards forelectrical equipment for use in flammable atmospheres.Any deviation from the specified installation conditions,or any unauthorized repairs or adjustments caninvalidate the safety assurances given by thecertification of the unit.

The ultimate responsibility for any particular installation lies withthe installing user/contractor.

This manual gives the installation, operating and maintenanceinformation for the Company's range of Models AK102 andAK103 Intrinsically Safe Gas Analyzer Systems, normally usedwith hydrogen cooled electrical power generators.

A complete AK10x Analyzer system uses a combination of threedifferent units. Each unit is certified independently for use as partof an intrinsically safe system to meet the standards of the ATEXdirective 9/94/EC for use in association with Group IIC(hydrogen) hazardous atmospheres in accordance with thefollowing standards:

The different units of the system are:

1) Model 6553 Display Unit, available in several variants. Theinputs to the unit are certified to code [Ex ia Ga] IIC (–20°C ≤Ta ≤ +40°C) under BAS 01 ATEX 7043 certificate with theunit installed in the safe area only.

2) Model 006539-960K (or J) and 006548-001 KatharometerUnits that form part of an intrinsically safe Model 006540-203 and 006548-000 Katharometer Analyzer Panel. Theseunits are certified to code Ex ia IIC T4 Ga (–20°C ≤ Ta ≤+55°C) under BAS 01 ATEX 1042 certificate for installationin the hazardous area (ZONE 0).

3) Model 4234 500 and 4234 501 constant current PowerSupply Unit provides the supply for one Katharometer Unit.These power supply units have their output certified to code[Ex ia Ga] IIC (–20°C ≤ Ta ≤ +55°C) under BAS 01 ATEX7041 certificate for installation in the safe area only.

If further information or assistance is required contact ourspecialist staff at one of the addresses shown on the back coverof this manual. Specialist training courses can also be arrangedat our Training Centre.

1 INTRODUCTION

0–97006NE&

11–97006NE

stinUretemorahtaK845600&935600tinUylppuSrewoP105/0054324

tinUyalpsiD3556

stinUretemorahtaK845600&935600

:gnisirpmoc*201KA)1x(tinuyalpsid3556

egrupdnaytirup-stinuretemorahtaK)2x(denibmocsag

)2x(USP4324

:gnisirpmoc*301KA)1x(tinuyalpsid3556

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.noitponasalacibucanidetnuomebnaC*

3

98.8H2—CO2

UIINON S E

Hydrogen Purity

& Purge Gas Monitor

Range

Range SelectorSwitches

DigitalDisplays

12

3

12

3

Zero

Zero

Range

F1

F2

ZeroAdjustment

AK102

All the various system options comprise one or more of thefollowing units with the further option of fitting the display andpower supply units in a cubicle.


2.1 Model 6553 Display UnitThe 6553 Display Unit must be mounted in a safe area and issuitable for panel mounting or installation into a control cubicle.The 6553 Display Unit houses one or two 4689 (or CM30) digitaldisplays, each equipped with a range selector switch andprotected access for zero adjustment – see Fig 2.1

The AK102 version is a dual 3-range instrument, designed toprovide 100% redundancy.

The AK103 version is a single 3-range instrument.

2.1.1 Range DisplayA selector switch for each display provides independentparameter selection as follows:

Position (1) Percentage of Hydrogen in Air by volume.This is the hydrogen purity measurement of thecoolant gas during normal operation of thesystem. The display covers a range of 85 to 100%or 80 to 100% hydrogen in air depending on therange selected. An alarm output and aretransmission signal (4 to 20mA) are provided forthis switch position only.

Position (2) Percentage of Hydrogen in CO2/Argon by volume.This range is for use in hydrogen filling or purgingoperation. Alarm and retransmission signals areinhibited in this switch position.

Position (3) Percentage of Air in CO2/Argon by volume.This range is for use in carbon dioxide (or argon)filling or purging operations. Alarm andretransmission signals are inhibited in this switchposition.

A further option of providing remote indication of range selectorswitch may be available, depending on the number of alarmsspecified.

The 4689 (or CM30) digital displays provide software specific tothe katharometer systems with relay action of the alarms fixed as'fail safe'. All user-programmable data can be protected fromunauthorized alteration by a programmable 5-digit securitynumber.

The zero adjustments on the front panel enable remote zeroingof the katharometers mounted in the hazardous area. Theadjustment access for a particular 4689 (or CM30) digital displayis adjacent to it at the same level.

The 6553 Display Unit has a protective case that can beremoved for access to the interior without removing the wholeunit from the control panel.

The 6553 Display Unit contains encapsulated zener diode safetybarrier devices to limit the electrical energy that can be suppliedfrom the instrument circuits into the hazardous area. Thesedevices are located below the 4689 (or CM30) digital display(s),on a rail that MUST be earthed to a high integrity earth point. Ametal screening arrangement segregates the connections madeto equipment in the hazardous area. The unit is protected on themains input side by two fuses, one for each circuit, accessiblefrom the front of the panel.

Fig. 2.1 Model 6553 Display/Control Units

2 DESCRIPTION

UIINON S E

Hydrogen Purity

& Purge Gas Monitor

Range SelectorSwitches

DigitalDisplay

12

3

Zero

Range

F1

ZeroAdjustment

AK103

4

OR OR

Terminal box to connect low flow

sensor to low flow alarms

Flow gauge with

integrated low flow

sensor (optional)

Optional labels – may or may not be fitted

B10KATHEROMETER

NO1

B12LOW FLOW

ALARM KATH NO1

B13LOW FLOW

ALARM KATH NO2

B11KATHEROMETER

NO2

ElectricalInterconnections

Gas SampleOutlet

Local ZeroAdjustment

KatharometerUnit Case

Drying Chamber

MeteringValve

GasSample

Inlet

2.2 Model 006540203 or 006548000Katharometer Analyzer Panel – Fig. 2.2Refer also to IM/6517-6518 for further details.Each panel comprises a metering valve, a drying chamber, athermally lagged katharometer (Model 006539 or 006548) and aflowmeter. These items are mounted on a flat panel suitable forfixing to a vertical surface close to the sample point. Thekatharometers are calibrated for the hydrogen puritymeasurement as well as hydrogen in carbon dioxide and air incarbon dioxide.

Each katharometer assembly incorporates a Wheatstone Bridgecomprising fine, glass-coated platinum filaments. One pair ofparallel arms is sealed in the reference gas and the other pairexposed to the sample gas.

When the intrinsically safe stabilized current from the 4234power supply unit (Model 4234 500 or 4234 501) is passedthrough this bridge, the temperature of the platinum filamentsrises to a point of thermal equilibrium. Under conditions that arearranged to give minimum radiation and convection heattransfer, the equilibrium temperature depends on the thermalconductivity of the gas surrounding the filament. Thus anydifference between the thermal conductivity of reference andsample gases causes an imbalance in the bridge; this imbalance(as a millivolt signal) is indicated by the display unit.

Zener diodes are connected across the input connections fromthe power supply unit to the katharometer in order to limit themaximum voltage that could be developed across the filamentbridge under external fault conditions. Under fault conditions thecurrent is limited to a safe value by the power supply unit.

2.3 Model 4234 500/4234 501Power Supply Units (PSU) – Fig. 3.3Refer also to IM/4234500 for further details.

Caution. Do not connect the mains supply to the PSUwith the output terminals open circuit.

Caution. Ensure that the PSU is correct for the mainssupply voltage available. A nominal 115V unit cannot beadapted for use with a nominal 230V supply, or viceversa.

To operate a katharometer unit in the hazardous area, one Model4234 PSU is required for each katharometer. The PSU suppliesa stabilized DC current output and must be mounted in the safearea. There are two versions available:

Model 4234 500 for a nominal 230V AC supply voltageModel 4234 501 for a nominal 115V AC supply voltage

The stabilized current output is current and voltage limited torestrict the energy supply into the hazardous area.

The PSU is housed in a metal case fitted with lugs for wall/panelmounting. Cable gland entries are provided at opposite ends ofthe case for supply voltage input and stabilized current outputcables to the hazardous area.

The circuit is protected by cartridge fuses. The fuses (F2 and F3)must have a high breaking capacity (HBC) rating of 1500A tocomply with the terms of the certification.

2.4 Remote Indicator/ControllersThe 6553 Display Unit has retransmission outputs forconnection to indicator/controllers, providing that they areinstalled in the safe area and the installation conforms to therequirements given in Section 5.1.

Fig. 2.2 Location of Items – Model 6540 203 and 6548 000 Katharometer Analyzer Panels

…2 DESCRIPTION

5

ABB LimitedOldends Lane, Stonehouse,Glos. England GL10 3TA

GAS MONITOR TYPE 6553

ll (1)G

BAS 01 ATEX 7043

1180 Ex IntrinsiSafety Label

98.8H2–CO2

UIIN O

N S E

Hydrogen Purity

& Purge Gas Monitor

Range

Zero

Zero

Range

1 23

1 23

F1

F2

ABB LimitedStonehouse England GL10 3TA

TYPE 4689/502 (or 505)SERIAL No. ......................

[Ex ia Ga] llC

ABB L i m i t e dOldends Lane, Stonehouse,Glos. England GL10 3TA

CodeSerial NoVoltageWatts Hz 50–60Year Manuf.Manufactured by:

Retaining Screw

N4006

4689 (or CM30) Digital Display

c

ABB LimiteOldends Lane, Stonehouse,Glos. England GL10 3TA

Katharometer Type 006548

IntrinsicSafety Label

Could also be006539

B12LOW FLOW

ALARM KATH NO1

B10KATHEROMETER

NO1

Ex

d

ll (1)G

Ex ia llC T4 Ga(–20ºC ≤ Ta ≤ +55ºC)BAS 01 ATEX 1042

N4006

✔


Type No.Serial No.Year of Manf.OutputZero GasRange

006548000

1180

Panel Reference No.

Model No.

UniqueReference No.

Gas Type

3.1 IdentificationIt is essential that installers and users clearly identify the variousunits of the monitoring system as follows:

3.1.1 Model 6553 Display Unit – Fig. 3.1Several versions of the 6553 Display Unit are available and aredefined by the code number explained in Section 3.1.4.

Identification and certification labels are fixed to the outside ofthe display unit case as shown in Fig. 3.1. Use the ordering codetable in Section 3.1.4 to interpret the identification label codeand obtain a precise description of the 6553 Display Unit.

Note. Location of the identification label on the 4689 (orCM30) digital display is also shown in Fig. 3.1.

3.1.2 Model 006540 203 or 006548 000Katharometer Analyzer Panel – Fig. 3.2Refer also to IM/6517-6518 for further details.The panel is identified by the reference number label as shown inFig. 3.2. The identification and certification labels of theindividual katharometer units (fixed to the katharometer case)

Fig. 3.1 Typical Identification Labels and Locations –Model 6553 Display Unit

Fig. 3.2 Typical Identification Labels with Locations –Model 006540 203 & 006548 000 Katharometer Analyzer

Panels (006548 shown)

3 PREPARATION

6


CodeSerial NoVoltage Freq.: 50/60HzWattsYear Manuf.Manufactured by: N4006

✔

ABB LimitedOldends Lane, Stonehouse,Glos. England GL10 3TA

TYPE 4234500/501 POWER SUPPLY UNITS

ll (1)G

[Ex ia Ga] llC (–20ºC ≤ Ta ≤ +55ºC)

BAS 01 ATEX 7041

Ex

IntrinsicSafety Label

1180

3.1.3 Model 4234 Power Supply Unit – Fig. 3.3Refer also to IM/4234500 for further details.The identification and certification labels are fixed to the outsideof the unit case, as shown.

Fig. 3.3 Typical Identification Labels and Locations –Model 4234 Power Supply Unit

…3 PREPARATION

Fig. 3.4 Typical Identification Labels and Locations –cubical option incorporating 6553 display unit and 4234

power supply unit

Product CodeSerial No.:Year Manufacture:Voltage:Frequency: 50/60HzPower Rating:Manufactured by:ABB LimitedOldends Lane, Stonehouse,

Glos. England GL10 3TA

N4006

7

3.1.4 AK10x Ordering Information

The equipment conforms with the requirements of ATEX directive for Class IIC gases to Code Ex ia IIC provided that the equipmentis installed in accordance with instructions provided.

3 PREPARATION

ATEX Compliant Gas Analyzer for Hydrogen-cooled Alternators AK10 X / X X X X X X X

Display Monitor Unit

Separate H2 Purity & Purge Gas DisplaysDual 3-range Displays (H2 Purity and 2 x Purge Gas)Single 3-range (H2 Purity and 2 x Purge Gas)Single Hydrogen Purity Display

1234

Hydrogen Purity Range

80/85% to 100%100% to 85% (does not conform to ATEX directive)100% to 80% (does not conform to ATEX directive)

123

Purge Gas

None (AK104 only)CO2ArgonNitrogen (AK101 only)

0123

Gas Analysis Panel *

NoneLow pressure & flame traps (for vent to atmosphere 0.35barg (5 psi) max.High pressure for closed loop 10barg (145 psi) max.

023

Cubicle

Without cubicleWith cubicle plus isolatorWith cubicle plus isolator plus MCBs and power supply indicators

023

Gas Sample Flow Alarm (only available with Cubicle option)

Not fittedOne flow alarm fitted AK103 and AK104 (single gas analysis panel versions)Two flow alarm fitted AK101 and AK102 (dual gas analysis panel versions)

012

Katharometer Power Supply ***

None115V 50/60Hz230V 50/60Hz

012

Special Feature

NoneSpecial

09

System Labels and Instruction Manuals**

EnglishFrenchGermanPolish

1237

***

***

Two Gas Analysis panels are required for AK101 and AK102Check with Factory for availabilityTwo Katharometer Power Supplies are required for AK101 and AK102

8

366

(14.

4)

KatharometerIntrinsically

Safe Circuits

SignalConventional

Circuits

CableEntry

Mounting PanelThickness

6 (0.24) max.

346

(13.

62)

30 (1.18)

Mou

ntin

g P

anel

Dis

play

Fac

e

350

± 0.

5 (1

3.78

±0.2

)(C

utou

t)

Panel Cutout andMounting Requirements

Area ForClamping

Cams

50(1

.97)

70(2

.76)

3 (0.12)278 ± 0.5 (10.94±0.2)(Cutout)

%H2 IN CO2

95.0

290 (11.4) 30 (1.18) 227 (8.94)

%H2 IN AIR

95.0

PowerInput

12

3

12

3

Not Fittedto AK103

3 (0.12)

4.1 Locating and Mounting System Items4.1.1 Models AK102 and AK103 Display Unit – Fig. 4.1

Note. The display unit must be located in the safe area of the application plant in a sheltered interior environment.

The display unit is designed for panel mounting in a position to suit reading of the displays and with access to the rear for electricalwiring interconnections. The panel preparation requirements and installation dimensions are shown in Fig. 4.1. The display unit issecured to the panel by four adjustable cam brackets – two each side of the unit chassis.

Dimensions in mm (in.)

Fig. 4.1 Installation Dimensions – Model 6553 Display Unit

4 MECHANICAL INSTALLATION

9

B12LOW FLOW

ALARM KATH NO1

B10KATHEROMETER

NO1

148 (5.83)

38 (1.5)

10(0.39)19

(0.7

5)

305

(12)

267

(10.

5)

610 (24)

572 ±0.3 (22.5±0.01)

233

(9.1

7)

Outlet

19 (0.75)

Gland for Ø7 to Ø10.5 (0.28 to 0.41) Cable

4 FixingHoles Ø10 (0.39)

Note 2. Terminal box fitted only to systems equipped with optional low flow alarm.

Note 3. A different type of flow gauge is fitted to systems not equipped with the optional low flow alarm – see Fig 6.1.

Note 1. Coupling forØ6 (0.24) Tube (006548000) orØ8 (0.31) Tube (006540203)

SeeNote 1

SeeNote 1

SeeNote 3

SeeNote 2

4.1.2 Katharometer Analyzer Panel – Fig. 4.2Refer also to IM/6517-6518 for further details.

Note. The panel is located in the hazardous area (Zone 0, 1 or 2) of the application plant in a sheltered interior environment.

Avoid a location that subjects the katharometer unit to direct sunlight. When two katharometer panels are used locate them inpositions that have the same ambient temperature.

The katharometer unit is fixed to the panel that has fixing holes at each corner for mounting on a suitable vertical surface close to thesample tapping point. The installation dimensions for the panel are shown in Fig. 4.2.

Fig. 4.2 Installation Dimension –Model 006540203 or 006548000 Katharometer Analyzer Panel


4 MECHANICAL INSTALLATION…

10

140

(5.5

) Cen

ters

110 (4.33) Centers

170 (6.7) 111 (4.37)

120

(4.7

2)

All Holes Ø7.0 (0.28)

160

(6.3

)

83

20 (0.79)

30(1

.18)

60 (2

.36)

Cen

ters

Ensure a clearance of at least 100 (4) atboth ends of the unit for acces to the cableglands and to minimize cable bends.

Mains CableEntry (Gray)

Not Used(Gray)

Output toKatharometer

3.0 (0.12)

20 (0.79)

30(1

.18)

30(1.18)

(Blue)

4.1.3 Model 4234 Power Supply Unit – Fig. 4.3Refer also to IM/4234500 for further details.

Note. The unit must be located in the safe area of the application plant in a sheltered interior environment.

The power supply unit has four fixing lugs for mounting on a suitable vertical surface. The installation dimensions are shown in Fig. 4.3.


Fig. 4.3 Installation Dimensions – Model 4234 Power Supply Unit

…4 MECHANICAL INSTALLATION

11

Hydrogen Purity& Purge Gas Monitor

ø12 (0.47) For use if cubicle is to be mountedon a shelf or similar horizontal surface(s)

* See page 6

12 3

Hazardous AreaCable Glands (Blue)

System Safety Earth (Mains Case Earth)

478(18.8)

600 (24.6)

140 (5.53)

80 (3.15)

80(3.15)340 (13.4)

382(15.04)

%H2 IN CO2

95.0

%H2 IN AIR95.0

4 Mounting BracketsØ10 (0.39) hole

12 3

515 (20.28) 40(1.57)

630 (24.8)

110(4.33)

Mains Isolator

Relays and 4 to 20 mAOutputs Cable Glands

IntrinsicallySafe Earth

4.1.4 Cubicle Mounted System – Figs 4.4 and 4.5The cubicle must be located in a safe area of the application plant and mounted either on the base using four M10 fixings or to avertical surface using the four fixing brackets on the back-plate.

Ensure any vertical surface on which the cubicle is to be mounted is robust and suitable for the purpose. Rawlbolts or similar heavy-duty fixings must be used.

Overall dimensions of the cubicle are given in Fig. 4.4 and the principal base case components are shown in Fig. 4.5.

Fig. 4.4 Installation Dimensions – Cubicle

Cubicle sealed to IP55

Weight of cubicle assembly 56kg (123lb) max.

Notes:• Suitable lifting equipment (for example, a crane or 2-man lifting sling) must be used to move the cubicle to its final

mounting location.• MCBs may or may not be fitted to AK102 and AK103 versions.

4 MECHANICAL INSTALLATION…


12

1 2 3 4 5 6 7 8 9 10 11 1312 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 L N L N38 39 40 41 42 43 44 45 46 47 48 49

Note. The number of terminals, cable glands, low-flow alarms, PSU's and zener barriers(flow alarms) vary according to ordering information details specified.

B6POWER SUPPLY

UNIT No. 1

B9LOW FLOW

ALARM RELAY No. 2

B8LOW FLOW

ALARM RELAY No. 1

No. 1 No. 2 B4 B5

BARRIER FLOWALARM

E SCR S1 S2 0V 0V -12V+12V

CH 1

I N COM NC NO

1 2 1 2

3 4 3 4

Low Flow AlarmZener Barriers

1 and 2(if iftted)

1 2

Low Flow AlarmRelay 2 (if fitted)

Earth Point (Ground)(NOT intrinsically safe earth)

Low Flow AlarmRelay 1 (if fitted)

To Isolator Earth

Cable Glands for CableTerminations in

Hazardous Areas (Blue)

Cable Glands forCable Terminations

in Safe Areas

To Cubicle Earth(NOT intrinsically safe earth)

To DisplayPanel Earth

Power SupplyUnit 2 (if fitted)

Power SupplyUnit 1

B7POWER SUPPLY

UNIT No. 2

MAINSSUPPLY

TB7

MAINSSUPPLY

TB6

TB10ALARM ANDRETRANS 2

TB11ALARM ANDRETRANS 1

No1 No2TB12

O/P FLOW ALARMS

TB13LOW FLOWALARM 2

TB14LOW FLOWALARM 1

PSU 2 TOKATH 2TB15

PSU 2 TOKATH 1TB17

KATH 2TB16

KATH 1TB18

Terminal Block

IntrinsicallySafe Earth

System Safety Earth

Fig. 4.5 Location of Main Components on Cubicle Backplate

…4 MECHANICAL INSTALLATION

4.2 Sample Gas Interconnections

Note. A hazardous mixture of hydrogen in air could develop in the event of leakage from the sample gas system. Mountkatharometer analyzer panels in a ventilated area.

The sample pressure must not exceed 0.35 bar (Gauge) for Model 6540 203 or 10 bar (Gauge) for Model 6548 000.

The incoming sample gas temperature must not exceed 55°C (131°F). Ideally the sample gas temperature should be allowed to reachambient temperature before entry to the Katharometer unit.

If there is a risk of significant particle contamination incorporate a suitable 1μm filter unit in the system before the sample gas entersthe analyzer system.

Compression couplings are supplied at the sample inlet and outlet to the katharometer panel. These couplings are suitable forconnecting 8mm (0.31 in.) (Model 006540 203) or 6mm (0.24 in.) (Model 006548 000) outside diameter metal tube. It isrecommended that stainless steel tube is used.

The complete tubing system should be tested for leaks in accordance with the requirements of the responsible authority.

13

Saf

e A

rea

See

Not

e 9

See Note 1

Not

e 1

App

arat

us w

hich

is u

nspe

cifie

d ex

cept

that

it m

ust n

ot b

e su

pplie

d fro

m n

or c

onta

in in

nor

mal

or a

bnor

mal

con

ditio

ns a

sou

rce

of p

oten

tial w

ith re

spec

t to

eart

h in

exc

ess

of 2

50 v

olts

r.m

.sor

250

vol

ts d

.c.

Not

e 2a

The

capa

cita

nce

and

eith

er th

e in

duct

ance

or

the

indu

ctan

ce to

resi

stan

ce (L

/R) r

atio

of t

heca

ble

conn

ecte

d be

twee

n th

e +

and

– te

rmin

als

of th

e po

wer

sup

ply

Type

423

4500

/501

and

term

inal

s 1

and

4 o

f a k

atha

rom

eter

Typ

e 00

65XX

mus

t not

exc

eed

the

follo

win

g va

lues

:

Haz

ard

ous

Are

a

See

Not

es 2

& 3

for

cabl

e de

tails

23

14

23

14

23

14

TB5

1817

TB6 19 20

PO

WE

R S

UP

PLY

TYP

E 4

234

500/

501

CE

RTI

FIE

D [E

x ia

Ga]

IIC

(–20

°C≤

Ta ≤

+55

°C)

CE

RTI

FIC

ATE

No

BA

S 0

1 AT

EX

7041

- +

21 3 21 3RS

1

RS

2

B1

B2

B3

Gas

Mo

nito

r T

ype

6553

– +

Indi

cato

reg

468

9

I1

– +

Indi

cato

reg

468

9

I2

4 –

1+ 9 10 3 –

2+

KAT

HA

RO

ME

TER

TYP

E 0

065X

XX

CE

RTI

FIE

D E

x ia

IIC

T4

Ga

CE

RTI

FIC

ATE

No

BA

S 0

1 AT

EX

1042

3 –

2+ 10 4 –

1+6 –

9

KAT

HA

RO

ME

TER

TYP

E 0

065X

XX

CE

RTI

FIE

D E

x ia

IIC

T4

Ga

(–20

ºC ≤

Ta

≤ +

55ºC

)

(–20

ºC ≤

Ta

≤ +

55ºC

)

CE

RTI

FIC

ATE

No

BA

S 0

1 AT

EX

1042

Junc

tion

boxe

s (if

requ

ired)

see

not

e 6.

Loca

tion:

Haz

ardo

us A

rea

or S

afe

Are

a

See

Not

e 1

See

Not

e 1

Junc

tion

boxe

s (if

requ

ired)

see

not

e 6.

Loca

tion:

Haz

ardo

us o

r S

afe

Are

a

RV

1

RV

2

Gro

upC

apac

itanc

ein

μF

Indu

ctan

cein

mH

L/R

rat

ioin

μH

/Ohm

IIC IIB IIA

7.63

113

999

0.05

0.14

0.37

22 88 177

or

Gro

upC

apac

itanc

ein

μF

Indu

ctan

cein

mH

L/R

rat

ioin

μH

/Ohm

IIC IIB IIA

38 999

999

0.40

1.20

3.20

75 225

600

or

Gro

upC

apac

itanc

ein

μF

Indu

ctan

cein

mH

L/R

rat

ioin

μH

/Ohm

IIC IIB IIA

40 999

999

0.05

0.16

0.43

52 210

421

or

Gro

upC

apac

itanc

ein

μF

Indu

ctan

cein

mH

L/R

rat

ioin

μH

/Ohm

IIC IIB IIA

40 999

999

0.37

1.37

3.28

79 316

632

or

Not

e 2b

The

capa

cita

nce

and

eith

er th

e in

duct

ance

or

the

indu

ctan

ce to

resi

stan

ce (L

/R) r

atio

of t

he c

able

sco

nnec

ted

betw

een

(a) t

erm

inal

s 17

& 1

8 of

the

gas

mon

itor

type

665

3 an

d te

rmin

als

9 &

10

of a

kat

haro

met

er T

ype

0065

XX, (

b) te

rmin

als

19 &

20

of t

he d

ispl

ay/c

ontr

ol u

nit a

nd te

rmin

als

9 &

10

of a

kat

haro

met

er T

ype

0065

XX, (

c) te

rmin

al 4

& 5

of b

arrie

r B

1 of

gas

mon

itor

type

6653

and

term

inal

s 2

& 3

of a

kat

haro

met

er T

ype

0065

XX, m

ust n

ot e

xcee

d th

e fo

llow

ing

valu

es:

Not

e 2c

The

capa

cita

nce

and

eith

er th

e in

duct

ance

or

the

indu

ctan

ce to

resi

stan

ce (L

/R) r

atio

of t

he c

able

sco

nnec

ted

betw

een

4 &

5 o

f bar

rier

B2

plus

term

inal

4 o

f bar

rier

B3

of g

as m

onito

r ty

pe 6

653

and

term

inal

s 2,

3 &

6 o

f a k

atha

rom

eter

Typ

e 00

65XX

, mus

t not

exc

eed

the

follo

win

g va

lues

:

See

Not

es 2

& 3

for

cabl

e de

tails

Circ

uit A

Circ

uit B

(see

Not

e 8)

Not

e 3

The

cabl

e m

ay b

e se

para

te c

able

s or

may

be

inst

alle

d as

sep

arat

e ci

r

Not

e 2d

The

capa

cita

nce

and

eith

er th

e in

duct

ance

or

the

indu

ctan

ce to

res

ista

nce

(L/R

) rat

io o

f the

cab

les

conn

ecte

dbe

twee

n te

rmin

als

3 &

4 o

f bar

rier

B1

of g

as m

onito

r ty

pe 6

553

and

term

inal

s 2

& 3

of K

athe

rom

eter

type

006

5XX,

m

ust n

ot e

xcee

d th

e fo

llow

ing

valu

es:

cuits

with

in a

type

‘A’ o

r a

type

‘B’

mul

ticor

e ca

ble

as d

efin

ed in

EN

6007

9 -

14: 2

008,

12.

2.28

(lat

est e

ditio

n) s

ubje

ct to

the

follo

win

g:a.

Eac

h ci

rcui

t sha

ll be

indi

vidu

ally

scr

eene

d w

ithin

a ty

pe ‘A

’ mul

ticor

e ca

ble.

b.Th

e pe

ak v

olta

ge o

f any

oth

er c

ircui

t with

in a

type

‘B’ m

ultic

ore

cabl

e m

ust n

ot e

xcee

d 60

vol

ts.

Not

e 4

The

inst

alla

tion

mus

t com

ply

with

nat

iona

l req

uire

men

ts (e

.g. i

n th

e U

K E

N60

079-

14: (

late

st e

ditio

n))

.N

ote

5Th

e sy

stem

mus

t be

mar

ked

with

a d

urab

le la

bel.

The

labe

l sho

uld

appe

ar o

n or

adj

acen

t to

the

prin

cipa

lite

m o

f ele

ctric

al a

ppar

atus

in th

e sy

stem

or

at th

e in

terfa

ce b

etw

een

the

intr

insi

cally

saf

e an

d no

n-in

trin

sica

lly s

afe

circ

uits

.Th

is m

arki

ng s

hall

incl

ude

the

wor

d S

YS

T or

SY

STE

M, e

.g.

‘BA

S S

YS

TEM

No

Ex

01E

2044

’ or

‘BA

S N

o E

x 01

E20

44 S

YS

T’N

ote

6A

junc

tion

box,

if u

sed,

mus

t sat

isfy

the

requ

irem

ents

of C

laus

es 6

.1 a

nd 6

.3.1

of E

N60

079:

11 (l

ates

t edi

tion)

.N

ote

7C

ircui

t A o

r C

ircui

t B m

ay b

e om

itted

.N

ote

8C

ircui

t B m

ay b

e id

entic

al to

Circ

uit A

.N

ote

9Th

is it

em m

ay o

r m

ay n

ot b

e fit

ted.

PO

WE

R S

UP

PLY

TYP

E 4

234

500/

501

CE

RTI

FIE

D [E

x ia

Ga]

IIC

(–20

°C≤

Ta ≤

+55

°C)

CE

RTI

FIC

ATE

No

BA

S 0

1 AT

EX

7041

- +

See

Not

e 10

Not

e 10

Zene

r bar

riers

(B1,

B2

& B

3) M

TL 7

755a

c B

AS

01

ATE

X 72

17 &

IEC

Ex B

AS

04.

0025

.

Dis

play

/Con

trol

Uni

tM

odel

655

3C

ER

TIFI

ED

[Ex

ia G

a] II

C(–

20ºC

≤ T

a ≤

+40

ºC)

CE

RT

No

BA

S 0

1 A

TEX

7043

& IE

CE

x B

AS

04.

0025

2a

2b

2d 2c

2b

2a

5.1 Electrical Interconnections – Fig. 5.1

Fig. 5.1 System Diagram

5 ELECTRICAL INSTALLATION

14

Warning.• Equipment in this system operates on AC mains

supply voltage electricity. Suitable safetyprecautions must be taken to avoid the possibility ofelectric shock.

• The mains supply to the equipment must be able toisolate the equipment independently. For example,use a switched spur or a mains isolator correctlyrated according to the regulations of the country inwhich the equipment is being used.

• The means of isolation must be located as close tothe equipment as possible and must not beobstructed.

Caution.• Although certain instruments are fitted with internal

fuse protection, a suitably rated external protectiondevice, either a 3A fuse or miniature circuit breaker(MCB) must also be fitted by the installer.

• The proper electrical connections and wiringstandards must be achieved to establish the intrinsicsafety of the system, as certified.

• AC input, intrinsically safe DC output and non-intrinsically safe wiring must all be routed separately.

Fig. 5.1 shows the interconnecting wiring requirements for theAK10x Gas Analyzer system, that must be strictly observed.Details of cable requirements, that must be strictly adhered to,are also given – see Section 5.2.1.

Zero Adjustmentfor RemoteKatharometers(only 1 fitted to AK103)

ClampCam

Mains Power Supply Fuses500mA HBC 250 V AC F,5x20 mm Ceramic(only 1 fitted to AK103)

3-way MainsSupply TerminalBlocks

Type 4689 (or CM30)Digital Display

Type 4689 (or CM30)Lower Digital Display(AK102 only)

Zener Diode SafetyBarrier Devices.Only Barrier B1 Fittedto Model AK103

Terminal Block (TB5 & TB6)for Katharometer Zero Pots.(Intrinsically Safe Circuits)

Mains & Case EarthTerminal

Terminal Blocks forPower and SignalConventional Circuits

Range Switch

Range Switch(AK102 only)

L N E 161

TBTS1

1

TB2

TB3

TB4

TB5 TB6

B1 B2

TB2 not fittedto AK103

TB4 not fittedto AK103

TB6 not fitted

TB-IS EarthConnect only to theIntrinsically Safe Earth(High Integrity Earth) incompliance withEN60079-14

to AK103

12

34

12

34

After completing the wiring, check that the continuity earthing(grounding) and isolation of all circuits is to the required localelectrical standards for intrinsically safe circuits.

The separate units of the Analyzer system must beinterconnected as shown in Sections 5.1.1, 5.1.2 and 5.1.3.

5.1.1 Model 6553 Display Unit – Fig. 5.2

Caution.• Do not make connections to the hazardous area

terminals (Terminal Blocks TB5 & TB6) other thanthose specified in wiring diagram Fig. 5.3. Theappropriate cable requirements must be strictlyadhered to.

• The earthing of B1 and B2 via TB-IS Earth must be inaccordance with EN 60079-14. The cable must beinsulated and the conductor must be 4mm2 crosssectional area minimum.

Remove the outer case from the back of the unit to gain accessto the terminal blocks.

Make electrical connections through the bottom of the unit intothe terminal blocks immediately above them – see Fig. 5.2.

The alarm and signal outputs on terminal blocks TB3 & TB4 maybe connected as required. The availability of signal outputs varywith the particular 6553 system – refer to Fig. 5.3 for details.

Continued on page 17.

Fig. 5.2 Location of Components Inside Case (Rear View) – Models 6553 Display Units

…5 ELECTRICAL INSTALLATION

15

Ext

erna

lpo

wer

sup

ply

TB2 1 2 3 4 5 6 7 8 9 10

Kat

haro

met

erU

nit

Gas

Pan

el 2

*TB

11 2 3 4 5 6 7 8 9 10

Kat

haro

met

erU

nit

Gas

Pan

el 1

TB1

TB2

Pow

er S

uppl

y U

nit 2

Mo

del

4234

LN

ETB

1TB

2

Pow

er S

uppl

y U

nit 1

LN

E

Ext

erna

lpo

wer

sup

ply

No

te. I

nter

conn

ectio

nsm

arke

d w

ith

M

US

T co

nfor

m to

the

intr

insi

cally

saf

e w

iring

requ

irem

ents

give

n in

the

text

.

All

othe

r w

iring

to s

uit p

ower

and

sig

nal

requ

irem

ents

Out

puts

as

requ

ired

(upp

er a

nd lo

wer

dis

play

s id

entic

al)

Zene

r di

ode

safe

tyba

rrie

r de

vice

sE

xter

nal d

ual

pow

er s

uppl

yC

onne

ctio

ns fo

rLo

wer

Dis

play

TB

-IS

Ear

th(In

trin

sica

lly S

afe

Ear

th)

Con

nect

ions

for

Upp

er D

ispl

ay

L N

E

LN

E

12

34

56

78

910

1112

1314

1516

TB4

NO

NC

NO

NC

CO

MC

OM

Rem

ote

Ran

ge(if

fitt

ed)

H2

in A

irA

larm

1

H2

in A

irVa

lue

Ret

rans

mis

sion

+

–

12

34

56

78

910

1112

1314

1516

Ext

erna

l bon

ding

and

eart

h

TS1

H2

in A

irA

larm

2

TB3

1718

1920

B1

4

3B

24

3

TB5

TB6

TB1 *

TB2 N

ote

.K

atha

rom

eter

Gas

Uni

t Pan

el 1

is c

onne

cted

inte

r nal

ly w

ithin

655

3 G

as M

onito

r to

Upp

er D

ispl

ay.

Kat

haro

met

er G

as U

nit P

anel

2 is

con

nect

ed in

tern

ally

with

in 6

553

Gas

Mon

itor

to L

ower

Dis

play

.

B1

4

5B

24

5

MTL

775

5ac

MTL

705

5ac

**

*

*

*

* **

**

Not

app

licab

le to

AK

103.

Old

er v

ersi

ons

only

.

Mo

del

4234

Mo

nito

r

Common

Range 3

Range 2

Range 1 + –+ –

+ –+ –

+–

+–

Fig

. 5.3

Inte

rco

nnec

tio

n W

irin

g D

iag

ram

– M

od

els

AK

102

& A

K10

3 In

trin

sica

lly S

afe

Ana

lyze

r S

yste

m u

sing

Dua

l 3-r

ang

e D

isp

lays

, as

Sep

arat

e U

nits

5 ELECTRICAL INSTALLATION…

16

12

34

56

7

89

1011

1213

4647

4849

3839

4041

4243

4445

L N

1415

1617

1819

2021

2223

2425

2627

2829

3031

3233

3435

3637

L N

Kat

haro

met

ers

Uni

t 1

Uni

t 2U

nit 1

Uni

t 2U

nit 1

Uni

t 2

Uni

t Nº

2U

nit N

º 1

TB8

TB7

TB14

/13

TB12

1413

From

PS

U1

From

PS

U2

Blu

e Te

rmin

als

Mai

ns T

/BA

larm

and

Ret

rans

mis

sion

1TB

11

Isol

ator

Uni

t(o

ptio

nal)

Ala

rm a

ndR

etra

nsm

issi

on 2

TB10

N/O

Common

N/CN/O

CommonN/C

N/O

Common

N/CN/O

CommonN/C

CommonRange 3Range 2Range 1

Cub

icle

Ter

min

al B

lock

s

+

–

+

–

H2 in AirAlarm 1

H2 in AirAlarm 2

H2 in AirAlarm 1

H2 in AirAlarm 2

Retransmission

Retransmission

Range SelectorSwitch Position

Indicator

Range SelectorSwitch Position

Indicator

23

910

14

Kat

haro

met

erP

anel

1

23

910

14

Kat

haro

met

erP

anel

2

Haz

ard

ous

Are

a

No

te.

Kat

haro

met

er P

anel

1 is

con

nect

ed in

tern

ally

to th

e U

pper

Dis

play

of t

he 6

553

Dis

play

/Con

trol

Uni

t.K

atha

rom

eter

Pan

el 2

is c

onne

cted

inte

rnal

ly to

the

Low

er D

ispl

ay o

f the

655

3 D

ispl

ay/C

ontr

ol U

nit.

Opt

iona

lLo

w F

low

Ala

rms

Ex

ia ll

C T

4

Opt

iona

lLo

w F

low

Ala

rm R

elay

s

23

14

23

14

CommonN/CN/O

CommonN/CN/O

Relay 1

Relay 2 *

Term

inal

Box

ScreenBlack

RedWhite

ScreenBlack

RedWhite

Kat

haro

met

erH

2 &

Air

in C

O2

H2

in A

ir

Kat

haro

met

erH

2 &

Air

in C

O2

H2

in A

ir

++

––

++

––

No

te. I

.S. C

ircui

tsIt

is im

pera

tive

that

wiri

ng in

stru

ctio

ns a

re fo

llow

ed im

plic

itly.

Ear

th c

ontin

uity

mus

t be

chec

ked

for

corr

ect b

ondi

ng.

War

ning

.Th

e ca

se-m

ount

ed In

strin

sica

lly S

afe

Ear

th

stud

(see

Fig

. 4.5

) mus

t be

con

nect

ed to

th

e pl

ant H

igh

Inte

grity

Ear

th. T

he m

axim

um

resi

stan

ce fr

om th

is e

arth

stu

d to

the

plan

t H

igh

Inte

grity

Ear

th m

ust b

e <

0.1 Ω

. Thi

s ea

rth

is e

ssen

tial t

o th

e co

rrec

t ope

ratio

n of

th

e ze

ner

safe

ty b

arrie

r.

War

ning

.Th

e ca

se-m

ount

ed S

yste

m S

afet

y E

arth

stu

d (s

ee F

ig. 4

.5)

mus

t be

con

nect

ed to

an

eart

h po

int e

nsur

ing

that

the

max

imum

res

ista

nce

is <

1 Ω

. Thi

s is

to e

nsur

e op

timum

sa

fety

for

both

the

syst

em a

nd p

erso

nnel

/ope

rato

rs.

*

*

*

*

*

*

*

* No

te. N

ot a

vaila

ble

if si

ngle

Mod

el A

K10

3 is

fitt

ed to

the

cubi

cle.

CommonRange 3Range 2Range 1

1

L

L

N

NL

N

E

LN

E

23 4

Fig

. 5.4

Wir

ing

Dia

gra

m f

or

Cub

icle

-Mo

unte

d D

isp

lay/

Co

ntr o

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t


17

Zero AdjustmentPotentiometer

MeasuringUnit

TubingConnections

Terminal Block (TB1)

DummyRemote Zero

Resistor.

Remove WhenConnecting

Remote Zero.

Mounting Pillars

10

912

11

10

9

8

7

6

5

4

3

2

1

Inlet Outlet

–

–

–

+

+

Make the wiring connections in accordance with the information given in the wiring diagram Fig. 5.3 and Section 5.1.

Refer Fig. 5.4 for connections to cubicle-mounted display unit.

Caution. The integrity of the fail-safe operation of the zener diode safety barrier devices depends on an Intrinsically SafeEarth connection which must not have a resistance greater than 0.1Ω to the application plant earth (ground).

Make the Mains and Case Earth (Ground) connection at the stud (TS1) – see Fig. 5.2.

On completion of wiring and checks, replace the outer case and secure the clamping brackets to the mounting panel.

5.1.2 Model 006540 203 and 006548 000 Katharometer Analyzer PanelRefer also to IM/6517-6518 for further details.To gain access to the connection terminal block TB1:

1) Remove four screws in the cover of the katharometer unit.2) Remove cover

Make the electrical connections to the Display Unit in accordance with the information given in wiring diagrams in Figs 5.3, 5.4 and5.5 and Section 5.2.

The electrical connections are made at the terminal block (TB1) via the cable gland or any replacement gland to suit the intrinsicallysafe wiring requirements. When the appropriate interconnections have been made, if remote zero is to be used, remove the 510Ωdummy remote zero resistor from across terminals 9 and 10 and set the zero adjustment potentiometer on the katharometer to theapproximate mid-point.

Replace the cover when wiring is complete.

Fig. 5.5 Location of Components Inside Case – Model 006539 and 006548 Type Katharometer Unit

5 ELECTRICAL INSTALLATION…

18

TB1

T1

L N EF2 F3

Warning. Hazardous Voltages.There are no servicable parts in this unit.Return to the manufacturer if faulty or seekthe services of a qualified engineer.

Switch off the mains supply and disconnectit before removing the cover for any reason.

6

8

10

230

230V 115V

V

115 V

Output Current (mA) Links350 C to X250 D to X180 E to X

NO connections should be made topoints A or B

TB2

–

+

F1

BA

C X

D E

M5 Earth Stud Voltage Links

Cable Gland forAC Mains Input(Gray)

OutputCurrentLinks

Cable GlandNot Used(Gray)

Cable Gland forDC Output toKatharometer(Blue)

Mains InputTerminal Block

DC OutputTerminal Block

Fuses*

*Refer to the 4234 manual for fuse details.

5.1.3 Model 4234 Power Supply Unit – Fig. 5.6Refer also to IM/4234500 for further details.

Caution. Do NOT connect mains supply to the power supply unit with the output terminals on open circuit.

Note. Ensure that the power supply unit is correct for the mains supply voltage available. A nominal 115V unit cannot beadapted for use with a nominal 230V supply or vice versa. Check voltage link is set to correct supply voltage – see Fig. 5.6.

Remove the cover of the unit to gain access to the terminal blocks inside.

Identify the terminal block (TB1) adjacent to the transformer T1 and ensure the correct transformer tapping is used for the incomingmains supply, i.e.

link from tapping 6 to 10 for 230V, orlink from tapping 8 to 10 for 115V.

Make electrical connections in accordance with the information given in the wiring diagrams Figs 5.1 and 5.3 and the cable detailsin Section 5.2.1.

The electrical connections are made at terminal blocks TB1 and TB2 through the appropriate cable gland or any replacement glandto suit intrinsically safe wiring requirements. Secure the incoming cable by the cable clips adjacent to the terminal blocks.

Replace the cover when wiring is complete.

Fig. 5.6 Location of Components Inside Case – Model 4234 Power Supply Unit


19

5.2 Intrinsically Safe RequirementsThese requirements relate to the interconnecting wiring made toand from Model 6540 203 and 6548 000 Katharometer AnalyzerPanels in the hazardous area and those for remote ancillaryitems connected to the system.

Note. Those cables connecting between the cubicleTB's and components in the hazardous area(intrinsically safe circuits) enter the cubicle via the bluecable glands and terminate in the appropriate blueterminals on the cubicle DIN rail – see Fig. 4.4.

5.2.1 Cable RequirementsThe interconnecting cables between the various units of the gasanalysis system are subject to stringent limitations because ofthe requirements of the intrinsic safety certification. These arelisted below and detailed in Fig. 5.1.

Items installed in safe areas must use cable suitably ratedaccording to the regulations of the country in which theequipment is being used.

All cables entering the hazardous area must be kept separatefrom cables in the safe area. Cables entering the hazardousarea must not be run with other cables and terminations musthave an earthed screen to separate them from connections forother circuits. The detailed requirements are as follows:

1) Connections between Model 006540 203 or 006548000 Katharometer Analyzer Panels and the 4234 PSU

All cables from the Katharometer in the hazardous areamust have an inductance/resistance ratio not exceeding22μH/Ω (for Group IIC gases). Refer also to Fig. 5.1Note 2a. Also the maximum loop resistance of thisinterconnecting cable is limited to 1.5Ω; this may place alimitation on the length of the total cable run. These wiresare indicated by a in Fig. 5.3.

Twist single sheathed conducting cables together toreduce their mutual inductance and route themseparately from cabling for non-intrinsically safe circuitsin the safe area.

2) Connections between Model 006540 203 or 006548000 Katharometer Analyzer Panels and Model 6553Display Unit

Katharometer to display unit cables, carrying the outputsignals through zener barrier units inside the display unit,are subject to of a maximum inductance/resistance ratioof 79μH/Ω (for group IIC gases). Refer also to Fig. 5.1Note 2d. These wires are indicated by a in Fig. 5.3.

3) Connections between model 006540203 or006548000 Katherometer Analyzer panels and Model6553 Display Unit

Kathrometer 9 and 10 to 6553 Display Unit terminals TB5and TB6 cables are subject to a maximum inductance/resistance ratio 75μH/Ω. Refer also to Fig. 5.1 Note 2b.These wires are indicated by a in Fig. 5.3.

5.2.2 Interconnection CablesThe choice of wiring cable is restricted by the limitationsimposed by the certification parameters. Care must be taken toensure that the specification of the cable required forinterconnection lengths is such that the certification parameterlimits are not exceeded – see Fig. 5.1 Notes 2a, b, c & d and alsoNotes 3 & 4.

5.2.3 Installing Remote Ancillary ItemsAny indicator/controllers, or other electrical equipment,connected to TB1 of the Model 6553 Display Unit must not besupplied from, nor contain, a voltage source greater than 250VDC or 250V RMS with respect to earth.

5.2.4 Full Intrinsically Safe RequirementsFor systems to be modified or used with other gases the fullATEX requirements must be complied with as follows:

1) The total Capacitance and Inductance or Inductance toResistance ratio (L/R) of the cables connecting thekatharometer unit to the hazardous area terminals of thedisplay unit (TB2) and power supply unit terminals (TB1)must not exceed the values in Fig. 5.1.

2) Any junction boxes used in the hazardous or safe areasmust conform to ATEX Directive 9/94/EC, specificallyclauses 6.1 and 6.3.1 of EN60079–0 (2012) andEN60079–11 (2012).

When the AK10x gas analyzer system has been correctlyinstalled in accordance with the requirements for intrinsicsafety in Section 5.2 – refer to Section 6 for system set up.

5 ELECTRICAL INSTALLATION

20

ElectricalInterconnections

Flow Gauge

Gas SampleOutlet

Local ZeroAdjustment

Drying Chamber

KatharometerUnit Case

MeteringValve

GasSample

Inlet


6.1 Katharometer Analyzer Panel –Filling the Drying Chamber – Fig. 6.11) Remove the drying chamber on the katharometer analyzer

panel by unscrewing the large knurled nut at the base of thechamber. Pull the chamber down and out of the sealinggroove to remove it from the panel.

Note. The desiccant used in the drying chamber iseither granular anhydrous calcium sulphate or calciumchloride and absorbs moisture from the atmosphere.The drying chamber has a capacity of 140ml approx.and requires approx. 100g of desiccant to fill it. Fillingand resealing must be carried as quickly as possible.

2) Open a container of fresh desiccant and fill the dryingchamber.

3) Replace the drying chamber in its sealing groove andreposition the chamber to enable it to be secured and sealedby hand tightening the knurled nut.

4) Carry out an approved leak testing procedure before passingsample gas through the system.

6.2 Setting Sample FlowWhen all tubing interconnections have been made and externalparts of the sample system checked for leaks, carry out thefollowing procedure:

1) Supply calibration quality CO2 or Argon through the gasanalyzer system at the normal working pressure of theapplication plant and within the following limits:

Model 6540-203125mm H2O min. to 0.35bar (gauge) max.

Model 6548-000125mm H2O min. to 10bar (gauge) max.

Note. In some instances testing for leaks with CO2 orargon may not be considered an adequate check ofgas tight integrity in respect of the more penetratinghydrogen gas. Consideration should be given to theuse of a gas, such as helium, which has penetratingproperties nearer to that of hydrogen.

2) Slowly open the metering valve to give a nominal flowrate ofgas of 100 to 150ml min–1. Do not exceed the maximumflowrate 250ml/min.

3) Set the flowrate and shut off the calibration gas external tothe analyzer system.

4) Repeat this procedure for each katharometer analyzer panel,as required.

Fig. 6.1 Location of Components on Katharometer Analyzer Panel

6 SETTING UP

21

6.3 Electrical ChecksCarry out the electrical checks detailed in Sections 6.3.1 and6.3.2.

6.3.1 Power Supply Unit Output

Warning. This unit is part of the certified intrinsicallysafe system. Appropriate safety precautions must betaken to prevent any incendive electrical discharges inthe hazardous area when carrying out this task.

Testing the output may only be carried out with thehazardous area cable disconnected.

1) Electrically isolate the PSU.

2) Remove the cover from the PSU.

3) Disconnect the output wires to the hazardous area atterminals TB2+ and TB2–.

Warning. Ensure that proper electrical safetyprecautions are taken at all times when undertaking thisprocedure.

4) Switch on the PSU and check that the output measures350mA into a 14Ω load.

5) On completion of tests isolate the unit and reconnect theoutput wires to the hazardous area.

6.3.2 Zener Diode Safety Barrier DevicesZener diode safety barrier devices are fitted to the katharometersystem as detailed in Table 6.1 and are checked at the time ofmanufacture. To ensure absolute safety, check that the barriersare correctly earthed by carrying out an appropriate test beforeusing the katharometer system.

Warning .• The zener diode safety barrier devices are certified

intrinsically safe and form part of the certifiedintrinsically safe system. Appropriate safetyprecautions MUST be taken to prevent anyincendive electrical discharges in the hazardousarea when testing the barriers.

• If the tests identify a faulty barrier, it MUST bereplaced by a new unit OF THE SAME TYPE – seeTable 6.1. The barriers are sealed units and repairsARE NOT permitted.

6 SETTING UP

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Table 6.1 Zener Diode Safety Barriers

6.3.3 Checking Intrinsically Safe EarthCheck that the resistance between the earth terminalconnecting zener barriers in the 6553 Display Unit and theapplication plant system high integrity earth does not exceed0.1Ω. Also check the low flow alarm zener barrier (if fitted in thecubicle) and the application plant system high integrity earthdoes not exceed 0.1Ω.

22

%H2 IN AIR

AlarmLEDs

UpperDisplay Line

LowerDisplay Line

Membrane Switches

A – Advancing to Next Page

Parameter 1Parameter 2Parameter 3Parameter 4

Page 1Parameter 1Parameter 2Parameter 3

Page 2

Advance tonext page

For majorityof parameters

or

B – Moving Between Parameters

C – Adjusting and Storing a Parameter Value

New value isautomatically stored

Parameter Value Adjust

D – Selecting and Storing a Parameter Choice

Parameter XYZ

Select

Parameter 1

Parameter 2Parameter 3

Page X

Parameter 4

Advance tonext parameter

or

New value isautomatically storedor

7.2 Switch Familiarization – Figs. 7.1 and 7.2

Fig. 7.1 Location of Controls and Displays

Fig. 7.2 Function of the Membrane Switches

7 CONTROLS & DISPLAYS

7.1 Digital Displays – Fig. 7.1The 4689 (or CM30) digital display(s) mounted in the 6553Display Unit comprises a 5-digit, 7-segment digital upperdisplay line and a 16-character dot-matrix lower display line. Theupper display line shows actual values of hydrogen purity,hydrogen in air, air in carbon dioxide, alarm set points orprogrammable parameters. The lower display line shows theassociated units or programming information.

23

7 CONTROLS & DISPLAYS

7.3 Main Isolator Switch, Toggle switches and Miniature Circuit Breakers (MCBs)

Fig. 7.3 Main Isolator Switch, Toggle switches and Miniature Circuit Breakers (MCBs)

Toggle switch for system 1 to switch

system monitor (display) and

katharometer PSU in / out of circuit

MCB for monitor

(display) unit 1

Monitor no. 1 label

PSU no. 1 label

Low flow alarm

relay no. 1 label

Monitor no. 2 label

PSU no. 2 label

PSU no. 2 labelAmber indicators

MCB for katharometer

PSU monitor 1

Monitor no. 1 label

PSU no. 1 label

Switch no. 1 label

Monitor no. 2 label

PSU no. 2 label

Switch no. 2 label

Low flow alarm

relay no. 2 label

Toggle switch for system 2

to switch system 2 monitor

and katharometer PSU

in / out of circuit

MCB for monitor unit

(display) 2

MCB for katharometer

PSU monitor 2

MCB for low flow

alarm relay no. 2

Low flow alarm

relay no. 1 label

MCB for low flow

alarm relay no. 1

Mains label

Electrical mains isolator

Notes.All Miniature Circuit Breakers (MCBs) toggle switches and amber indicators are optional variants that may or may not be fitteddepending upon the customers’ order code.

1. MCB 0.5 A rated. These resettable MCBs provide additional electrical safety protection to personnel and circuits.

2. The toggle switches are fitted to enable the user to independently switch in/out the display, katharometer PSU and LowFlow Alarm of system 1 or the display, katharometer PSU and Low Flow Alarm of system 2 appropriately, from the mainelectrical supply circuit within the cubicle. When each switch is in the down position (marked ‘I’), the electrical supply isswitched ON to the display unit, katharometer PSU and Low Flow Alarm to each system. When each switch is in the upposition (marked ‘O’), the electrical supply is switched OFF to the display unit, katharometer PSU and Low Flow Alarmto each system. These switches are for operational use only. If any work is undertaken within the cubicle, the electricalmains isolator must be used to switch off the electrical power.

3. Amber indicators: these are illuminated when electrical mains power is present at the respective monitor units, eachkatharometer PSU and each Low Flow Alarm, as and when fitted.

4. The electrical mains isolator is fitted to enable the user to disconnect the complete cubicle unit from the electrical supply.For safety reasons, the isolator must always be switched to OFF when any work is to be carried out within the cubicle.

24

Warning. When the apparatus is connected to itssupply, terminals may be live and the opening of coversor removal of parts (except those to which access maybe gained by hand) is likely to expose live parts.


8.1 Instrument Start-UpIn normal operation, the range selector switch is set toposition 1 and the instrument displays the Range 1 OperatingPage – see Section 9.2. This is a general use page in which thealarm set points may viewed but not altered. To change an alarmset point or program a parameter refer to Section 10. A 5-digitSecurity Code is used to prevent unauthorized access toprogrammable parameters. The value is preset at 00000 to allowaccess during commissioning but should be altered to a uniquevalue, known only to authorized operators, as described in theSetup Outputs Page – see Section 10.3.

When all the required wiring connections and electrical checkshave been made correctly, switch on the power supplies to thevarious units as follows:

1) Switch on the supply to the PSU.

2) Switch on the supply to the 6553 Display Unit.

8.2 Alarm Set Point8.2.1 Type of Alarm ActionThe alarm relay coil is energized during normal non-alarm relaystates and is de-energized upon recognition of an alarmcondition, thereby providing 'fail-safe' alarms. For example, withAlarm 1 set point = 95.0%, when the display is indicating greaterthan 95.0% (plus hysteresis), Alarm Relay 1 is energized andAlarm 1 LED is OFF. When the display indicates less than 95.0%(minus hysteresis), Alarm Relay 1 is de-energized and Alarm 1LED is ON. This operating mode ensures that an alarm conditionis signalled in the event of a mains power failure. Repeat theabove procedure for Alarm Relay 2 set point = 90.0%.

8.2.2 Hydrogen Alarm Set PointIt is recommended that the hydrogen alarm set-points arebased on a reducing percentage of hydrogen as it is displacedby air entering the application plant. This can be achieved bysetting Alarm 1 and Alarm 2 to give ample warning of thedevelopment of a potentially explosive mixture. Factory settingsare Alarm 1 = 95.0% and Alarm 2 = 90.0%.

The procedure is as follows:

Access the programming pages (Section 10) and set the alarmset points in accordance with the information in the Set UpOutputs Page. The hydrogen alarm set point can only be set withthe selector switch in position 1.

8.3 Electrical CalibrationThe instrument is factory calibrated for electrical voltage signalinput. No adjustment is normally necessary for correctfunctioning of the display unit. If electrical calibration is required,a voltage source capable of supplying –250.00mV to 10.00 mVis needed. Disconnect the katharometer input from the displayunit and the voltage source signal applied according to theinstructions in the Electrical Calibration Page – see Section 10.

Note. The 4689 instruments incorporate a two pointcalibration sequence requiring both zero and spaninputs for a calibration. It is not possible to adjust eitherthe range zero or the range span scale pointsindependently.

8 START-UP

25

8 START-UP

8.4 Gas Calibration8.4.1 IntroductionBefore putting the system on-line, it is recommended that acalibration check for the 'zero' reading is made using calibrationstandard sample gas.

The 'zero gas' is marked permanently on the data plate of thekatharometer unit. This gas, when passed through thekatharometer, gives a zero millivolt output. To provide a fail-safecondition the zero gas is 85% hydrogen in nitrogen mixture sothat, if power is lost to the katharometer, an alarm conditionoccurs at the display unit.

Full scale output from the katharometer is obtained by a 100%hydrogen gas sample and no adjustment of the katharometeroutput is normally required. The maximum signal for the full scalereading is sealed during manufacture and must not be altered byusers.

With the katharometer adjusted correctly using the 'zero gas'hydrogen in nitrogen mixture, carbon dioxide (or argon) and airmixtures are displayed correctly when the selector switch is inthe appropriate position.

8.4.2 Gas Range Calibration

Note. Test for leaks in accordance with therequirements of the responsible authority for site safetyafter making any hydrogen connections.

Note. The procedure outlined here is not normallynecessary as the ranges have been set at the factory.

1) Select Range 1Pass an 85% H2/15% N2 gas mixture through thekatharometer and allow the reading to stabilize. Adjust thekatharometer zero potentiometer or remote zero (if fitted) togive a reading of 85% H2 in air.

2) Pass 100% H2 through the katharometer and allow thereading to stabilize. If necessary adjust the katharometerspan potentiometer (R7) to give a reading of 100% H2.

3) Select Range 3Pass 100% CO2 or Argon through the katharometer andallow the reading to stabilize. Adjust the katharometer spanpotentiometer (R7) to give a reading of 0% air in CO2/Argon.

4) Pass 100% air through the katharometer and allow thereading to stabilize. Adjust katharometer span potentiometer(R7) to give a reading of 100% air in CO2 or argon (only if thereading is greater than 100%).

5) Select Range 1Pass 100% H2 through the katharometer and allow thereading to stabilize. Adjust the katharometer zeropotentiometer or remote zero (if fitted) to give a reading of100% H2 in air.

6) Repeat steps 3) to 5) and adjust as necessary.

26

9.1.2 Filling with Hydrogen Coolant GasThis procedure is a reversal of the purging procedure.

Initially, inert purge gas (CO2 or argon) is introduced into theapplication plant until the air content is safely below theexplosive limit for air in hydrogen. When this limit is reached,hydrogen is gradually introduced into the system to displace theother two gases.

With respect to the operation of the gas analyzer system, theprocedure is as follows:

Warning. Suitable safety precautions apply to theoperation of the gas cooling and sample systems.

Note. For optimum accuracy it is recommended thatthe filling operation commences within 24 hours ofcarrying out the calibration procedure.

1) Select position (3) of the range selector switch of the displayunit. The displays and functions are shown in Table 9.1.

2) When the changeover to introduce hydrogen into theapplication plant is made, select range (2) of the rangeselector switch on the display unit. The displays andfunctions are shown in Table 9.1.

3) When the display indicates that hydrogen filling is complete,position the range selector switch at (1). The hydrogenmeasurement analyzer system is now ready for monitoringH2 concentration on-line – see Section 9.2.

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9.1 NormalDuring normal operation the AK10x Gas Analyzer System isused to indicate the purity of hydrogen used as a coolant. Thedisplay shows the percentage of hydrogen in air, which shouldbe safely in excess of the explosive limit at the hydrogen richend.

There are no routine adjustments required to the gas analyzersystem after completion of start-up procedures and putting on-line in monitoring mode. The system requires only the carryingout of safety routines and minor adjustments to the meteringvalve to maintain the required flowrate.

A summary of the functions and status of the system for thedifferent range selector switch positions is shown in Table 9.1.

9.1.1 Purging of Hydrogen Coolant GasInitially, inert purge gas (CO2 or argon) is introduced into thesystem. When the hydrogen concentration is safely below theexplosive limit, air is introduced into the system to completelydisplace the other two gases.

The AK10x Gas Analyzer System provides all the necessaryindications and output signals to enable this operation to becarried out safely.

In respect of the operation of the gas analyzer system(s), theprocedures are as follows:

Note. Suitable safety procedures apply to theoperation of gas cooling and sample systems.

1) Select position (2) of the range selector switch on the displayunit. The displays and functions are shown in Table 9.1.

2) Commence the purging operation.

3) When the changeover to introduce air into the applicationplant is made, select position (3) of the range selector switchon the display unit. The displays and functions are shown inTable 9.1.

Table 9.1 Functions and Status of Display Units for Different Range Selector Switch Positions

9 OPERATION

27

Alarm 1 Setpoint

Alarm 2 Setpoint

Press to advanceto next parameter

Press to advanceto next page

SECURITY CODE

0 0 0 0 0

or

SECURITY CODE

SECURITY CODE

%H2 IN AIR

%H2 IN CO2

AIR IN CO2

9.2 Range 1 Operating PageRange 1 is selected for normal operations and the Operating Page indicates the purity of the hydrogen used as a coolant. The alarmset points can be viewed but not altered. To change the alarm set points or program other parameters, refer to Section 10.

Hydrogen PurityShows the percentage of hydrogen in air.

These two keys are used to advance to all subsequent parameters and pages.

Alarm 1 Set PointThe set point value is programmmable – see Section 10.3, Set Up Outputs Page.

Alarm 2 Set PointThe set point value is programmmable – see Section 10.3, Set Up Outputs Page.

Advance to Access to Secure Parameters on page 28.

9.4 Range 3 Operating PageRange 3 is selected only during purging and refilling operations and the Operating Page indicates the percentage of Air in the CO2 orArgon purge gas. Access to the programming pages is not possible with range 3 selected.

Purge GasShows the percentage of Air in the CO2 or Argon purge gas.

9.3 Range 2 Operating PageRange 2 is selected only during purging and refilling operations and the Operating Page indicates the percentage of hydrogen in theCO2 or Argon purge gas. Access to the programming pages is not possible with range 2 selected.

Purge GasShows the percentage of hydrogen in the CO2 or Argon purge gas.

9 OPERATION

28

Range 1 Selected

Operating PageRange 1

English

SECURITY CODE

SET UP OUTPUTS

Set Up Outputs PageElectrical

Calibration Page

Access toSecure Parameters

xxx.xLanguage Page

No Yes

RTX Range 85%

Test Retrans (%)

Alter Sec. Code

Alarm 1 Setpoint

%H2 IN AIR

mV Span (10mV)

xxx.x

Adjust RTX Zero

Adjust RTX Span

mV Zero (-250mV)

xxx.x

Calibrate No

ELECTRICAL CAL

Secure Parameters

Note. All parameter values shown on the upperdisplay line are the default settings.

Range 2 SelectedOperating Page

%H2 IN CO2

Range 3 SelectedOperating Page

AIR IN CO2

Alarm 2 Setpoint

Note. With the range selector switch set to either Range2 or Range 3, only the respective Operating Page isdisplayed. Pressing the and keys has no effect.

Alarm 1 Set Point

Alarm 2 Set Point

RTX Type 0-10

0-20

4-20

Notes.• Access to the programming pages is possible only with Range 1 selected.• The following programming pages apply to both digital displays.

Fig. 10.1 Overall Programming Chart for Display Unit

10 PROGRAMMING

29

SECURITY CODE

English

10.1 Access to Secure ParametersA 5-digit code is used to prevent unauthorized access to the secure parameters.

Security CodeEnter the required code number, between 00000 and 19999, to gain access to thesecure parameters. If an incorrect value is entered, access to subsequent programmingpages is prevented and the display reverts to the Operating Page.

Note. The security code is preset at '00000' to allow access during commissioning butshould be altered to a unique value, known only to authorized operators – see AlterSecurity Code parameter in Set Up Outputs Page.

Note. Access to the programming pages is possible only with Range 1 selected.

Note. CO2 is refered to throughout this manual as the purge gas. However, other gases such as Argon or Nitrogen may beused instead.

Advance to Language Page.10.2 Language Page

Language PageSelect the required language for the display.

Advance to Set Up Outputs Page.

10 PROGRAMMING...

30

SET UP OUTPUTS

RTX Range 85%

xxx.xTest Retrans (%)

Alarm 1 Set Point

Alarm 2 Set Point

RTX Type 0-10

0-20

4-20

Alter Sec. Code

Alarm 1 Set PointThe set point band is defined as the actual value of the set point plus or minus thehysteresis value. The hysteresis value is fixed at 0.2% H2 in Air. Alarm action occurs if theinput value is above or below the set point band. If the input moves within the set pointband, the last alarm action is maintained.

The Alarm 1 Set Point can be set to any value within the input range being displayed. Thedecimal point position is set automatically. The alarm LEDs are illuminated in the alarmcondition.

Alarm 2 Set PointSee Alarm 1 Set Point.

Advance to next parameter

Retransmission Output TypeSelect retransmission output range required (4 to 20mA, 0 to 20mA or 0 to 10mA).


RTX RangeThe retransmission signal can be selected to be ranged 85 to 100% H2 in Air or 80 to100% H2 in Air. This option is only available with the range switch in position 1.


Test Retransmission OutputThe digital display transmits a test signal of 0, 25, 50, 75 or 100% of the retransmissionrange. The % test signal selected is shown on the upper line of the display.

Example – for the range 4 to 20mA and 50% retransmission test signal, 12mA istransmitted.

Select the required retransmission test signal.


Alter Security CodeSet the security code to a value between 00000 and 19999.This value will then have to be entered to regain access to the secure parameters.

Advance to Electrical Calibration Page.

10.3 Set Up Outputs Page


...10 PROGRAMMING

31

ELECTRICAL CAL

Calibrate No

xxx.xmV Zero (-250mV)

xxx.xmV Span (10mV)

Adjust RTX Zero

Adjust RTX Span

Yes No

Notes.1) The 4689 (or CM30) digital display incorporates a two point calibration sequence

requiring both zero and span inputs for a calibration. It is not possible to adjust therange zero or the range span scale points independently.

2) Each digital display is fully calibrated before despatch and should not normally requirefurther calibration.

Select Calibration

Select the calibration requirement using the or keys.

Calibrate No (default) skips to Adjust RTX Zero frame.

Calibrate Yes enables zero and span electrical calibrations to be carried out.Advance to next parameter

Calibration Range Zero (100% Purge Gas)Connect a suitable millivolt source (see Section 8.3) and apply a signal input equivalent torange zero (–250.00mV). Allow the instrument display to stabilize.


Calibration Range Span (100% H2 in Air)Apply a signal input equivalent to range span (+10.00mV). Allow the instrument display tostabilize.


Adjust Retransmission ZeroAdjust the retransmission zero (e.g. 4.00mA) to the appropriate zero value.The retransmission zero signal is either 85% or 80% H2 in Air as selected in Set UpOutputs Page.Allow the output signal to stabilize.Advance to next parameter

Adjust Retransmission SpanAdjust the retransmission span (e.g. 20.00mA) to the appropriate maximum value.The retransmission span signal corresponds to 100% H2 in Air.

Allow the output signal to stabilize.

Return to Operating Page.

10.4 Electrical Calibration Page


10 PROGRAMMING

32

The katharometer unit and its associated equipment aredesigned for stable and accurate operation over long periods.

This section covers the requirements for fault finding, diagnostictests and maintenance tasks.

Warning.• Each unit of this system forms an integral part of a

certified intrinsically safe system. Appropriate safetyprecautions must be taken to prevent any incendiveelectrical discharges in the hazardous area whencarrying out any of the following tasks.

• Equipment in this system operates at AC mainssupply voltages. Suitable precautions must be takento avoid the possibility of electric shock.

• The maximum pressure and temperature limitsspecified for particular parts of the system must notbe exceeded.

Note. After any service, repair or modification, thesuitably qualified personnel involved must certify thatthe equipment is in a safe state.

11.1 General Maintenance11.1.1 PressureThe operation of the katharometer units is not affectedsignificantly by changes in pressure providing that they are withinthe pressure limits – see Section 13.

11.1.2 FlowThe katharometer zero balance and sensitivity are independentof the sample flowrate, as the sample gas sensing systemdepends on molecular diffusion. However, the speed ofresponse is affected by the flowrate. This means that the flowresistance of the drying chamber is a compromise betweenobtaining speed of response and avoiding a rapid degradation ofthe desiccant.

11.1.3 LeaksThere is an inherent safety requirement that there are no leaksinto or out of the sample system. Any leaks could also affect thecorrect operation of the katharometer unit.

11.1.4 VibrationThe katharometer unit tolerates reasonable levels ofmechanically induced vibration. Pulsations due to unsteadysample flow can affect the katharometer filaments and causeerrors due to excessive cooling.

11.1.5 ContaminationContamination in the sample system can arise from oil orsuspended particles, or from erosion of material from the samplesystem upstream of the katharometer unit.

11.1.6 Ambient TemperatureThe calibration of the katharometer is not affected significantlyby variations of the ambient temperature. Temperature changescan affect the sensitivity and reduce accuracy on sensitiveranges.

11.1.7 Bridge CurrentThe working current of the katharometer bridge is 350mAsupplied from the PSU. This value must remain stable duringnormal operation as the katharometer output signal isproportional to the cube of the bridge current.

11 MAINTENANCE

33

PCB

Potentiometer

Katharometer Filament Block

Drain

Stand-offs

11.3.3 Changing Desiccant in Drying ChamberThe need to change the desiccant in the drying chamber on thekatharometer Analyzer panel depends on the condition of thesample gas.

It is recommended that the Analyzer system is monitoredregularly during the initial phase of operation for indications thatthe desiccant is exhausted. A suitable maintenance interval forthis task can then be established.

As the desiccant degrades, the white grains have a yellowishtinge and the granular form becomes more consolidated. If liquidcontamination occurs, the desiccant becomes brown andconsolidated.

Warning. Suitable safety precautions apply to theoperation of the gas cooling and sample systems.

a) Isolate the sample gas system from the main system. Carryout a limited hydrogen purging operation on the samplesystem in accordance with the instructions of theresponsible authority.

b) Fill the drying chamber – see Section 6.1.

c) After purging any residual air from the sample system inaccordance with the requirements of the responsibleauthority, allow hydrogen to pass through the katharometeragain.

This procedure should be undertaken on the basis of instrumentresponse or at intervals of 1 year.

Fig. 11.1 Removing Liquid from theKatharometer Filament Block

11 MAINTENANCE...

11.2 Diagnostic Tests

Warning.• Each of the units in the system are part of the

certified intrinsically safe system. Appropriate safetyprecautions must be taken to prevent any incendiveelectrical discharges in the hazardous area whencarrying out this task.

• Ensure that the proper electrical safety precautionsare taken at all times when undertaking thisprocedure.

11.2.1 Checking Output of the PSUCarry out the test procedure in Section 6.3.1.

11.2.2 Checking Integrity ofZener Diode Safety Barrier DevicesCarry out the test procedure in Section 6.3.2.

11.2.3 Checking the Katharometer Outputa) Electrically isolate the display unit.

b) Remove the outer cover from the katharometer unit.

c) With the katharometer operating, check if the voltage acrossterminals TB1 – 1 and TB1 – 4 is not above 4V with 350mApassing. If the voltage is above this value it is likely that oneor more filaments of the bridge is broken.

d) With the katharometer operating, check that the voltageacross terminals TB1 – 1 and TB1 – 4 is below 2.8V with350mA passing. If the voltage is below this value and there isno zero adjustment available, it is likely that there is anaccumulation of liquid within the katharometer block – seeSection 11.4.1.

e) If the reading from the test made at step c) is unstable whenthe katharometer block is tapped gently, this could indicatethat a filament is damaged but not open circuit.

If any of these tests indicate that the katharometer is faulty thecomplete katharometer unit must be returned for repair orreplacement.

The span adjustment of katharometer units are sealed and mustnot be adjusted unless necessary – see Section 8.4.2.

11.3 Routine Maintenance11.3.1 Hydrogen Katharometer CalibrationCarry out a calibration check in accordance with Section 8.

Calibration should be carried out at intervals of 3 months of on-line use.

11.3.2 Purge Gas Katharometer CalibrationCarry out a calibration check in accordance with Section 8.3.

Calibration should be carried out before using the katharometerfor monitoring a purging procedure.

34

o) Isolate the katharometer unit at its PSU.

p) Make the remaining electrical connections at TB1 of thekatharometer unit – see Fig. 5.5 on page 17.

q) Replace the cover of the katharometer unit.

r) Power up the katharometer unit from its PSU.

s) Carry out a calibration procedure – see Section 8.3.

Note. It is possible that the zero reading may drift forseveral days after the removal of liquid.

11.4.2 Removal/Replacement of a 4689 (or CM30)Digital Displaya) Electrically isolate the 6553 Display Unit.

b) Release the retaining screw through the display facia andcarefully withdraw the chassis from its edge connectors andout through the front panel – see Fig. 3.1 on page 5.

c) To replace the digital display, carefully insert it into the displayfacia and press firmly into position before tightening theretaining screw.

d) Power up the 6553 Display Unit and carry out a calibration –see Section 8.3.

11.4.3 Error MessagesIf the error message 'NV Memory Error' is displayed the contentsof the non-volatile memory has not been read correctly duringpower up.

To rectify the fault, switch off, wait 10 seconds and switch onagain. If the fault persists, contact the Company.

...11 MAINTENANCE

11.4 Repair Maintenance11.4.1 Removing Liquid fromKatharometer Measurement Block – Fig. 11.1If tests indicate that there is likely to be an accumulation of liquidin the katharometer filament block, remove the liquid using thefollowing procedure:

a) Electrically isolate the defective katharometer at its PSU.

b) Isolate the gas sample system to the particular katharometerfrom the main gas cooling system. Purge the sample systemof hydrogen in accordance with the requirements of theresponsible authority.

Caution. The thermal insulation inside the case mustnot be damaged or removed.

c) Remove the cover of the katharometer unit and dismantlethe internal sample system pipework.

d) Remove the fixing screws securing the mounting pillars tothe case – see Fig. 5.5.

e) Disconnect the interconnecting wiring at terminal block TB1.

Caution. Do not insert any type of probe into the gassystem of the katharometer filament block assembly oruse compressed air to blow through the system.

f) Remove the katharometer filament block assembly from thecase and tilt at 45° to the horizontal. This allows any liquid todrain from the measurement block – see Fig. 11.1.

g) Pour a small quantity of rectified spirit (ethanol) through thekatharometer filament block. Allow as much liquid aspossible to drain out. Assist this by gentle shaking. Repeatthis procedure several times until all evidence ofcontamination is removed.

h) Fit the katharometer filament block assembly into its case.Replace the fixing screws and make the electricalinterconnections at terminals TB1 – 1 and TB1 – 4.

i) Fit the internal sample gas tubing.

j) Remake the sample gas tube interconnection couplings.

k) Replace the desiccant in the drying chamber in accordancewith the procedure in Section 11.3.3.

l) Carry out a leak test in accordance with the requirements ofthe responsible authority.

m) Power up the katharometer unit by switching on theappropriate PSU.

n) Pass dry air or another suitable dry gas through thekatharometer at the normal sample flowrate for 24 hours.

35

12.3 Repair Maintenance PartsDescription Part No.Model 4234 Power Supply Unit

Nominal 230V unit 4234/50000Nominal 115V unit 4234/50100Fuses

F2/F3 – T250mA/≥1500A 250VAC HBCceramic cartridge 20 x 5 mm 0231577F1 – 400mA cartridge 0231555

Katharometer Low pressure High pressureAnalyzer Panel 006540 203 006548 000

Drying chamber cylinder - Acrylic 006525 710 006525 720Drying chamber cylinder - Stainless Steel 006548 111Drying chamber complete - Acrylic 006525 600 006548 003Drying chamber complete - Stainless Steel 006548 110Flowmeter (Without flow alarms) 006525 440 0216 485Flowmeter (With flow alarms) 0216 557Valve, metering 006540 361 0216 484Coupling seal ring 006525 130

Katharometer unit 006539 960K (or J) 006548 001

Model 6553 Display UnitDescription Part No.

Display units Carbon dioxide purge 4689/502Display units Argon purge 4689/505Zener diode safety barrier devices MTL 7055ac 0248 297Zener diode safety barrier devices MTL 7755ac 0248 296

Low Flow Alarm (If Fitted)Description Part No.

Zener diode safety barrier devices MTL 767+ 0248 298

12 SPARE PARTS LIST

Warning. Interference with any unit or its componentsimplies acceptance of responsibility by that person forensuring the continuing maintenance of intrinsic safetyrequirements. Unauthorized repair/ use of spare partsor incorrect assembly may render any unit unfit for usein an intrinsically safe application.

Note. Although the 4689 digital displays may bemarked 4600 on their display facia, they are dedicatedvariants which are not interchangeable with theCompany's standard 4600 Controller/Display. Thesededicated display units are identified (4689 502) asshown in Fig. 3.1 on page 5.

When ordering a katharometer unit, it is necessary to specify thezero gas and range in association with the Company partnumber. See the typical identification label shown in Fig. 3.2 onpage 5.

12.1 Consumables Description

12.2 Routine Maintenance PartsDescription Part No.Model 6553 Display Unit

Fuse, 500mA 250VAC rated F 20 x 5 mm ceramic cartridgeHBC (1500A) 250VAC 0231 601Function selector switch AK103 & AK102version Upper Switch 006553 511Function selector switch AK102 version Lower Switch 006553 512Potentiometer (1kΩ), zero adjustment 002569 036

Katharometer Low pressure High pressureAnalyzer Panel 006540 203 006548 000

Drying chamber refurbishment kit 006525 605 006548 007Granular anhydrous CaCl2 006537 580 006537 580

36

13 CERTIFICATES

CE Declaration of Conformity certificates are available from theCompany on request or can be downloaded from our website:www.abb.com/analytical.

EC Declaration of Conformity – Gas Monitor type6553

EC Declaration of Conformity – Type 4234500/501 Power Supply Units

EC Declaration of Conformity – Katharometerstype 006539 and 006548

37

14 SPECIFICATION

Specification

6553 Gas MonitorApprovals

CENELEC approved

[Ex ia Ga] IIC (–20°C Ta +40°C)

BASEEFA Certificate No. BAS 01 ATEX 7043

II (1)G

EN61010-1:2010 Compliant

Ranges(a) 80% or 85% to 100% H2 in air

(b) 0 to 100% H2 in Purge Gas *

(c) 0 to 100% air in Purge Gas *

Range Selector Switch Positions (when fitted)1 – percentage by volume, hydrogen in air

2 – percentage by volume, hydrogen in purge gas *

3 – percentage by volume, air in purge gas *

Accuracy (display units)± 0.25% of scale span

Ambient Temperature Range0 to 40°C (32 to 104°F)

Power Supply110/120V AC or 200/220/240V AC, 50/60Hz(two separate versions)

Fuse RatingF1 / F2 500 mA, 250 V AC rated 1500 A @ 250 V AC, HRC, ceramic, fast blow

Power Consumption30VA approximately

Outline Dimensions290 x 362 x 272mm (11.4 x 14.25 x 10.9 in.)

Weight12kg (26.4lb)

EnvironmentSheltered interior, 0 to 90% RH

Outputs and Set PointsNo. of relays

AK101 – Three (Two for H2 Purity, One for Purge Gas)

AK102 – Four (H2 Purity)

AK103 – Two (H2 Purity)


Relay contacts

Insulation 2kV RMS contacts to earth (ground)

Remote range indication

No. of set pointsAK101 – Three (Two for H2 Purity, One for Purge Gas)

AK102 – Four (H2 Purity)



Set point adjustmentProgrammable

Set point hysteresis±1% fixed

Local set point annunciationRed LED

RetransmissionNo. of retransmission signals

AK101 – Two fully isolated (One for H2 Purity, One for Purge Gas)

AK102 – Two fully isolated

AK103 – One fully isolated

AK104 – One fully isolated (H2 Purity)

Output current0 to 10mA, 0 to 20mA or 4 to 20mA programmable

Accuracy±0.25% FSD ±0.5% reading

Resolution0.1% at 10mA, 0.05% at 20mA

Max. load resistance750 (20mA max.)

* Note. Purge gas options include:

CO2

N2

Ar

(Carbon dioxide)(Nitrogen)(Argon)

Single pole changeover

Rating 250V AC 250V DC max.

3A AC 3A DC max.

Loading (non-inductive) 750VA 30W max.

(inductive) 75VA 3W max.

Rating 250V AC 300V AC max.

150mA AC 150mA AC max.

38

14 SPECIFICATION

DS/AK100-EN Rev. M

4234 Power Supply UnitApprovals

CENELEC approved

[Ex ia Ga] IIC (–20°C Ta +55°C)


II (1)G

EN61010-1:2010 Compliant

Power Supply115V AC 50/60Hz (4234501) or

230V AC 50/60Hz (4234500)

Power Consumption30 W Max.

Fuse RatingT250mA 250 V AC rated 1500 A HRC ceramic, 250 V AC rated 20 x 5 mm

DC Output350mA stabilized ±0.14%

Load Conditions

Ambient Temperature Range–20 to 55°C (–4 to 131°F)

Supply Variations±15V (115V supply) or ±30V (230V supply) 46 to 64Hz

RegulationWithin ± 0.5% for:

Load variation of ± 15%

Supply variation of ± 15%

Ambient temperature variation of ± 20°C (36°F)

±4Hz frequency variation

RippleLess than 0.5% of set output peak/peak across a 10 load

StabilityWithin ± 0.7% of initial setting, over period of 1 month with loadresistance, supply voltage and ambient temperature at nominal statedvalues

Overall Dimensions160 x 170 x 110mm (6.3 x 6.7 x 4.3 in.)

Weight2.12kg (4.8 lb) approx.

EnvironmentSheltered interior

6540–203 and 6548–000 Katharometer Analyzer PanelApprovals

CENELEC approved

Ex ia Ga IIC (–20°C Ta +55°C)


II (1)G

Model 6540–203 incorporating Model 6539–960 (H2) or Model 6539–960 (Purge Gas) Katharometer Unit

Model 6548–000 incorporating Model 6548–001(H2 and Purge Gas) Katharometer Unit

Power Supply350mA DC, from 4234500 or 4234501 power supply unit

Signal Output0 to 10mV for each range (Air in N2 1.0mV)

Accuracy± 2% of scale span, each range± 5% of scale span, Air in N2

Dead TimeTypically 5s

Response TimeTypically 40s for 90% step change at KatharometerTubing and drying chamber introduce extra delays

Ambient Temperature55°C (131°F) max.0°C (32°F) min.

Sample ConnectionsCompression couplings:

6mm OD tube (Model 6548-000)

8mm OD tube (Model 6540-203)

Sample PressureMinimum 125mm H2O

Sample Temperature0 to 55°C (32 to 131°F)

Normal Sample Flowrate100 to 150ml/min.

Maximum Gas Flowrate250ml/min

Minimum Gas Flowrate50ml/min

Outline Dimensions610 x 305 x 152mm (24 x 12 x 6 in.)

Weight8.6kg (18.9lb)

EnvironmentSheltered interior

1 Katharometer 13 max.

Interconnecting cable 2 max.

Maximum 0.35bar (Gauge) Model 6540–203

Maximum 10bar (Gauge) Model 6548–000

39

NOTES

40

...NOTES

Products and customer supportAutomation SystemsFor the following industries:— Chemical & Pharmaceutical— Food & Beverage— Manufacturing— Metals and Minerals— Oil, Gas & Petrochemical— Pulp and Paper

Drives and Motors— AC and DC Drives, AC and DC Machines, AC Motors to

1kV— Drive Systems— Force Measurement— Servo Drives

Controllers & Recorders— Single and Multi-loop Controllers— Circular Chart and Strip Chart Recorders— Paperless Recorders— Process Indicators

Flexible Automation— Industrial Robots and Robot Systems

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Marine Systems & Turbochargers— Electrical Systems— Marine Equipment— Offshore Retrofit and Refurbishment

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Transmitters— Pressure— Temperature— Level— Interface Modules

Valves, Actuators and Positioners— Control Valves— Actuators— Positioners

Water, Gas & Industrial Analytics Instrumentation— pH, Conductivity and Dissolved Oxygen Transmitters and

Sensors— Ammonia, Nitrate, Phosphate, Silica, Sodium, Chloride,

Fluoride, Dissolved Oxygen and Hydrazine Analyzers— Zirconia Oxygen Analyzers, Katharometers, Hydrogen

Purity and Purge-gas Monitors, Thermal Conductivity

Customer supportWe provide a comprehensive after sales service via a Worldwide Service Organization. Contact one of the following offices for details on your nearest Service and Repair Centre.

UKABB LimitedTel: +44 (0)1453 826661Fax: +44 (0)1453 829671

USAABB Inc.Tel: +1 215 674 6000Fax: +1 215 674 7183

Client WarrantyPrior to installation, the equipment referred to in this manual must be stored in a clean, dry environment, in accordance with the Company's published specification.Periodic checks must be made on the equipment's condition. In the event of a failure under warranty, the following documentation must be provided as substantiation:— A listing evidencing process operation and alarm logs

at time of failure.— Copies of all storage, installation, operating and

maintenance records relating to the alleged faulty unit.

Contact us

IM/A

K1/

23 R

ev.

N08

.201

6ABB LimitedProcess AutomationOldends LaneStonehouseGloucestershire GL10 3TAUKTel: +44 1453 826 661Fax: +44 1453 829 671

ABB Inc.Process Automation125 E. County Line RoadWarminsterPA 18974USATel: +1 215 674 6000Fax: +1 215 674 7183

www.abb.com

NoteWe reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents in whole or in parts – is forbidden without prior written consent of ABB.

Copyright© 2016 ABBAll rights reserved

http://www.abb.com

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User Guide IM/AK1/23 Rev. N AK102 and AK103 Gas analyzer … · 2018. 5. 9. · 3.1.1 Model 6553...

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